Optical Measurements That Drive Progress

Nowadays, automotive development is driven by the need for ever higher efficiency levels. Lightweight construction, electrification and downsizing are the characterizing “factors” in industry. Simulation tools bypass entire development cycles in this regard. Valid tests and the measuring technology used there bridge the gap between the virtual world (simulation) and the real world of prototypes.

The Polytec vibrometers’ optical vibration measurement technology guarantees non-intrusive data in a quality that satisfies the high simulation and efficiency standards encountered in everyday testing operations – even for lightweight structures. You can put Polytec’s measuring technology to versatile use: on the test bench, in the modal test, in vehicle acoustics or in sensor development. eEven if everything doesn’t always go to plan, with the Polytec vibrometers you can always rest assured that you’ll get reliable decision capable data and quick problem visualization even during troubleshooting operations. So you’ll always achieve the outcome you’re after in the end.

Minimizing Noise and Wear

As the drivetrain is the initial source of noise, wear and even driving discomfort, understanding its dynamics is vital if a vehicle is to be a success. Polytec’s optical measuring technology lends your production facilities a helping hand with tasks where they need it most: from inspecting the stroke of the injection valve needle, over characterizing the valve elevation curves, to measuring torsional vibration at the downforce transmission paths. You can also establish the design of cardan and constant velocity drive shafts and characterize dual-mass flywheels for better driving comfort.

Polytec’s laser vibrometers have next to no frequency limitations, so, working together with you, they cover the entire scope of use for any acoustic and structural dynamic phenomena. This is precisely why they are so well-suited to analyzing high-frequency phenomena such as rattling and whining sounds in the gearbox. Scanning measurements, on the other hand, use detailed operational deflection shapes to illustrate solution processes, with a view to preventing acoustic radiation through the enclosure.

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The HSV-100 High Speed Vibrometer allows you to simultaneously measure displacements and vibrational velocities up to 40 m/s. To measure the valve train dynamics, the system can be expanded to include as many channels as you like and allows you to compensate...

The Scanning Vibrometer provides you with a flexible vibration measurement platform that can be expanded at any time and that you can use to quickly and intuitively complete the most challenging vibration measuring tasks. This testing solution makes recording...

The RLV-5500 Rotational Vibrometer measures the angular velocity and angular displacement of rotational vibrations on any shape of rotating structure. It precisely analyzes the rotational dynamics of drivetrains, gas turbines, electrical generators, printers...

Optimizing Lightweight Construction with Greater Precision

Lightweight construction forms the basis for better construction. The body shell offers the best potential in this regard. High tensile steels, aluminum and composite materials made from carbon fiber-reinforced plastic are being used instead of auto body steel. Joining methods such as bonding and riveting are entering production processes, making simulation calculations susceptible to faults since joint attenuation cannot be determined with any real degree of certainty. Consequently, proof from an experimental modal analysis is more important than ever before during FE model validation.

Since work is carried out with fewer prototypes nowadays, optimization steps need to be faster and more reliable. Even lightweight bodies tend to drone, which is precisely why high-frequency mode validation is a topic for the future too as regards the acoustic calculation. A well-validated inventory model is normally used as a basis for the next generation. The better the model, the earlier a new vehicle’s properties can be calculated.

Lightweight bodies need lightweight measuring technology. So light isn’t the only ideal sensor. In offering you the 3D Scanning Vibrometers and the automated RoboVib® solution, Polytec is providing you with a highly productive tool that is extremely beneficial to you:

No impact on the sample

Measurement geometries are adopted straight from the calculation department

Automatic measurement in a fraction of the time when compared with conventional methods

High spatial resolution for acoustic simulation validation

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The Scanning Vibrometer provides you with a flexible vibration measurement platform that can be expanded at any time and that you can use to quickly and intuitively complete the most challenging vibration measuring tasks. This testing solution makes recording...

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Keeping Noises Under Control

Following vehicle development, product quality very much depends on the production process. To avoid unwanted noise and, therefore complaints, engines and gearboxes alike have to be subjected to a complete check. The non-contact measuring technology used in the Polytec vibrometers has proven to be the most efficient measuring method here too.

Ancillary units such as compressors or fans are disturbing sources of noise, particularly with respect to new electric drive concepts. Vibration measurements performed with Polytec vibrometers instantly give you information about the design quality – both during the development phase and at the final acceptance stage. The components are put through their paces prior to installation – so your customers will be happy with the end result.

The vibrometer provides you with threefold assistance in this regard: in NVH (“noise, vibration, harshness”) development, when you are selecting the test points to measure structure-borne sound, and as a sensor for measurement without the need for a feed mechanism. Dirt or contact do not influence the measurement’s reliability and reproducibility, since the sensor does not touch the surface. Not only does this increase your earnings; it drastically reduces reject rates too.

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The flexible vibration-measuring device with an integrated camera and a compact design is ideal for quality assurance and research. Additional microscope lenses expand the range of possible tasks that you can complete to include very small samples.

All the Measurement Data in Next to No Time

In-vehicle noise is very much dominated by wind noises of more than 80 km/h. A reliable check is carried out in an aeroacoustic wind tunnel with extensive force, flow and sound pressure measurements. The excitation of outer surfaces – particularly the windshield, rear window and undercarriage – caused by turbulences on the vehicle’s body shell is extensively recorded by a scanning vibrometer. The excited deflection shapes have to be recorded without influencing the flow.

The Scanning Vibrometers from Polytec allow you to capture the necessary measurement data, without having to go through the time-consuming process of vehicle instrumentation, with short measuring times all around – even if you’re trying to capture data from below through a glass base.

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Effectively Eliminating Noises

Braking systems exhibit different acoustic behaviours depending on the vehicle. Careful vibration set-up is absolutely essential for quiet braking. The complex eigenvalue analysis illustrates unstable operating conditions during the simulation process. The results of the experimental modal analysis ensure that the models are updated with maximum precision.

Polytec’s 3D Scanning Vibrometers enable you to validate even small components such as brake pads for a bottom-up approach. The measurement technique remains the same, even during the final test on the air-conditioned NVH test bench. The high spatial resolution records all the high-frequency modes that are characteristic of squealing. Non-contact measuring technology also provides you with reliable data for troubleshooting and model validation even on hot brakes.

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Reliably Identifying Sources of Noise

It is impossible to imagine modern vehicles without electronics. Not only do electronics control vehicles; they are increasingly powering them too. This is precisely why reliable electronics are critical for market success. Vibration and impact loads are therefore extensively tested prior to SOP.

The non-contact vibration sensors from Polytec are ideal for dealing with these problems. The high-sensitivity laser technology reliably detects vibration-related weak points on printed circuit boards or individual components, right down to individual bond wires. Modal tests and order analyses quickly provide the right data for component, PCB, enclosure and attachment optimization.

The additional noises produced by pumps, adjusting drives and fans can be heard much more clearly if the combustion engine is not being used as a masking noise factor in electric or hybrid vehicles running in electric mode. There is also the high-performance electronics, which add a new source of high acoustic sharpness to the vehicle acoustics.

Laser vibrometers from Polytec enable you to visualize and quantify the transfer path in the vehicle interior and to identify the source of noise right on the electronics board. Scanning and single-point vibrometers are therefore the products of choice of OEM and tier 1 suppliers the world over.

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Significantly Shortening Modal Tests

Experimental modal analysis (EMA) is used to confirm (validate) or correct (in a process known as “model updating”) simulation results of a finite element calculation (finite element model = FEM). Designing components based on a finite element model is an efficient way of shortening development times. But the feasibility of the resulting structural dynamic models needs to be assessed. Consequently, it is essential to perform the experimental modal test on prototypes so as to validate the models.

Scanning Vibrometers from Polytec speed up this process significantly and offer you a multitude of benefits. The measurements you perform are non-contact, so they do not influence the vibrational characteristics. The FE-like spatial data density means you can perform a modal analysis for higher modes and meaningful MAC analyses. The measurement grid is generated from the FE network and an identical coordinate system is used instead of just being interpolated. Generally speaking, you can use any number of “virtual” measurement points and thereby achieve high spatial resolution – regardless of how many sensors and channels are available.

Polytec’s Scanning Vibrometers use a software-controlled laser beam as a sensor and are therefore compatible with CAE measuring technology. They achieve a high level of data quality and are ideal for swift acoustic model validation too. Even overnight testing is possible – with the fully automatic RoboVib® Structural Test Station.

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Making Vehicles Quieter

Droning, humming, squeaking and rattling are typical acoustic problems found in vehicles – and particularly in lightweight construction. They are a source of irritation to end customers and consequently need to be eliminated. The term NVH (noise, vibration and harshness) is an umbrella term used to refer to all those measures that enhance acoustic comfort for drivers and passengers alike.

Developing quiet, low-vibration products is a joint simulation and testing task. Polytec’s Scanning Vibrometers allow you to unveil sources of sound radiation quantitatively and with high spatial resolution. Inverse panel contribution measurements and qualification of damping materials (sound package) are made a great deal easier with the automatic scanning process.

You can use a Scanning Vibrometer to examine the source of sound excitation in detail and, in so doing, identify the structure-borne sound transmission paths and the causative deflection shape. The 3D visualization of the operational deflection shapes helps the NVH engineer to quickly come up with ideas to solve the problem – even just before production starts.

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The Scanning Vibrometer provides you with a flexible vibration measurement platform that can be expanded at any time and that you can use to quickly and intuitively complete the most challenging vibration measuring tasks. This testing solution makes recording...

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